Curled manifold for evaporator

ABSTRACT

A manifold for use in a heat exchanger assembly and a method of forming the manifold is disclosed herein. The assembly includes an upper manifold defining an interior and having a upper top portion having an upper opening in the center of said upper top portion. A partition is inserted through the upper opening to define a plurality of chambers in the interior. The partition has a plurality of locking tabs and dimples that abut the upper top portion. The method starts with the step of forming the upper manifold defining an interior and having an upper top portion defining an upper opening in the center of the upper top portion. The method continues with the step of dividing the upper manifold to define a plurality of chambers in the interior of the upper manifold and is finalized by joining the partition and the upper manifold through a snap fit.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to manifolds having multiple passages. Morespecifically, the invention relates to multi-pass manifolds.

2. Description of the Prior Art

Air-cooling (or heating) cross-counter flow heat exchangers are oftenused in applications where space limitations restrict the surface are ofthe heat exchanger. Cross-counter flow heat exchangers typically includea plurality of stacked, assembled modules, with each module including apair of spaced manifolds interconnected by a plurality of spaced andparallel tubes. The modules are stacked such that air flows in adirection perpendicular to the face of the heat exchanger, and air finsare disposed between adjacent pairs of tubes for transferring heat fromthe tubes to the passing air. U.S. Pat. No. 6,581,679 granted to Fisherdiscloses a heat exchanger having an upper manifold defining an interiorand having an upper top portion and an upper lower portion. U.S. Pat.No. 5,582,239 granted to Tsunoda discloses an upper manifold having apartition.

There is a need for more efficient heat exchangers and methods ofmanufacturing the same.

SUMMARY OF THE INVENTION

In summary, the invention provides a manifold for use in a heatexchanger assembly and a method of forming the manifold. The methodstarts with the step of forming an upper manifold defining an interiorand having an upper top potion defining an upper opening in the centerof the upper top portion and an upper bottom portion defining aplurality of spaced upper tube slots. The method is finalized by thestep of dividing the upper manifold to define a plurality of chambers inthe interior of the upper manifold and joining the partition and theupper manifold through a snap fit.

The apparatus includes a partition disposed in the upper manifold todefine a plurality of chambers in the interior of the upper manifold.The partition has a plurality of spaced projections and a plurality ofspaced upper recesses that extend longitudinally straight along acentral axis for accepting the projections.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be readily appreciated, as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanying drawingswherein:

FIG. 1 is a perspective view and exploded view of the exemplaryembodiment of the invention;

FIG. 2 is a perspective view and exploded view of a second embodiment ofthe invention;

FIG. 3 is a front view of the upper manifold;

FIG. 4 is a cross-sectional view of the tubes taken along line 3-3 ofFIG. 2;

FIG. 5 is a front view of the partition;

FIG. 6 is a perspective view of the partition of the second embodiment;

FIG. 7 is a perspective view of the upper manifold;

FIG. 8 is a perspective view of the upper manifold including thepartition;

FIG. 9 is a perspective view of the upper manifold of a thirdembodiment; and

FIG. 10 is a perspective view of the upper manifold of the embodiment ofFIG. 9.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT

Referring to the Figures, like numerals indicate corresponding partsthroughout the several views. Referring to FIGS. 1 and 2, a heatexchanger assembly is generally shown and includes an upper manifold 20defining an interior. Referring to FIG. 3, the upper manifold 20 has anupper top portion 22 and an upper bottom portion 24. The upper topportion 22 has a semi-circular or curved shape and an upper opening 26in the center of the upper top portion 22. Referring again to FIG. 2, alower manifold 28 is spaced and parallel from the upper manifold 20. Theupper bottom portion 24 of the upper manifold 20 defines a plurality ofspaced upper tube slots 30 and the lower manifold 28 defines a pluralityof spaced lower tube slots 32.

A plurality of tubes 34, each having flat sides 36 and round ends 68,extend between upper and lower tube ends 38, 40 in the upper and lowertube slots 30, 32. Each of the tubes 34 extend parallel and spaced fromone another and define a plurality of air or refrigerant passages 42there between. The tube slots 30, 32 include a plurality of rows of tubeslots 30, 32 one on each side of said central axis A and the tubes 34include a plurality of rows of tubes 34 one on each side of said centralaxis A and are disposed in the tube slots 30, 32.

Referring to FIG. 2, an air fin 46 is disposed between and is brazed tothe flat sides 36 of the tubes 34. The air fin 46 extends between theupper and lower manifolds 20, 28 for dissipating heat from the tubes 34.Referring to FIG. 1, an end cap 44 is disposed on each end of themanifolds 20, 28. The lower manifold 28 further defines an interior andhas a lower top portion 60 and a lower bottom portion 62

A partition 48 is disposed in the upper manifold 20 and defines aplurality of chambers 50 in the interior of the upper manifold 20. Thepartition 48 has a plurality of spaced projections 58. The upper bottomportion 24 has a plurality of spaced upper recesses 64 extendinglongitudinally straight for accepting the projections 58. The partition48 defines a plurality of holes 56 for conveying refrigerant through themanifold. The holes 56 may be gradient as shown in FIG. 1, orconsistent, as they extend along the partition 48. The holes 56 may alsobe any shape or frequency to facilitate communication between the firstand second passes of the manifolds 20, 28.

In a second embodiment and as shown in FIGS. 2, 5, 6, 9, and 10, thepartition 48 has a plurality of spaced and alternating locking tabs 52disposed on the opposite end as the projections 58 for abutting the topportion at the exterior of the upper manifold 20. The partition 48 alsohas a plurality of spaced dimples 54 for abutting the top portion 22, 60at the interior of the upper manifold 20 to form a snap fit through theopening 26. The dimples 54 have a ramp-like shape when looking at aplane normal to the partition 48 and as shown in FIG. 5. The upper topportion 22 is made of a material that may bend to allow the dimple 54 ofthe partition 48 to be inserted through the opening 26. Further, theupper top portion 22 and the lower top portion 24 are a single pieceforming the upper manifold 20.

When applied to an Inlet/Outlet manifold, the partition 48 prevents therefrigerant from flowing from one chamber 50 to another. When applied toa return manifold, the partition 48 includes holes 56 that allow therefrigerant to flow from one chamber 50 to the other. The partition 48also acts as a stiffener and provides additional strength.

Referring to FIGS. 9 and 10, a third embodiment includes a four passheat exchanger. The top portions 22, 60 of the manifolds 20, 28 have atleast one slot 66 extending from the side opposite of the locking tabs52. At least one separator 70 is included for insertion into the slots66 in the top portions 22, 60, dividing the interior of the manifolds20, 28 into more than two chambers 50.

The invention also includes a method of forming a manifold for use in aheat exchanger assembly. The method starts with the step of forming anupper manifold 20 defining an interior and having an upper top portion22 defining an upper opening 26 in the center of the upper top portion22 and an upper bottom portion 24 defining a plurality of spaced uppertube slots 30. The method continues with the step of dividing the uppermanifold 20 to define a plurality of chambers 50 in the interior of theupper manifold 20. The method proceeds with the step of joining thepartition 48 and the upper manifold 20. The joining step includesinserting projections 58 from the partition 48 into spaced recesses 64defined by the bottom portion of the manifold. The joining step alsoincludes projecting a dimple 54 from the partition 48 and providing anopening 26 in the upper top portion 22 and elastically forming theopening 26 of the upper top portion 22 and sliding the dimple 54 throughthe opening 26, creating a snap fit.

The method continues with the step of permanently fixing the partition48 to the upper manifold 20. The method proceeds with the step ofpermanently fixing at least one locking tab 52 disposed on the partition48 to the exterior of the upper top portion 22 of the upper manifold 20wherein the permanent fixing is further defined as brazing. The methodproceeds with the step of forming a plurality of tubes 34 extendingbetween upper and lower tube ends 38, 40 and defining a plurality of airor refrigerant passages 42. The method continues with inserting theupper tube ends 38 of each tube 34 into one of the upper tube slots 30of the upper manifold 20 to establish fluid communication between thepassages 42 of the tubes 34 and the chambers 50 of the upper manifold20.

The method continues with the step of forming a lower manifold 28defining an interior and having an lower top portion 60 defining and alower bottom portion 62 defining a plurality of spaced upper tube slots30 aligning with the upper tube slots 30. The method further continueswith the step of inserting the lower tube end 40 of each of the tubes 34into the corresponding lower tube slot 32 of the lower manifold 28 toestablish fluid communication between the passages 42 of each tube 34and the lower manifold 28.

The method proceeds with the step of forming an air fin 46 betweenadjacent tubes 34 to dissipate heat from the tube 34. The method iscompleted with the step of inserting a separator 70 into the topportions 22, 60 for dividing the interior of the manifolds 20, 28 intomore than two chambers 50.

It is to be understood that “upper” and “lower” as used in the presentapplication are arbitrary, inasmuch as a heat exchanger in accordancewith the present invention can be oriented in different directions.Therefore, “upper” and “lower” should be understood to be used withreference to the orientation of the manifolds 20, 28 and tubes 34 asshown in the drawings herein, and is not limiting the orientation of themanifolds 20, 28 or tubes 34 in actual use.

While the invention has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teaching of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. A manifold assembly for a heat exchanger: an upper manifold definingan interior and having a upper top portion and an upper bottom portion;said upper top portion having an upper opening in the center of saidupper top portion; a partition for insertion through said upper openingfor defining a plurality of chambers in the interior of said uppermanifold; and said partition having a plurality of spaced projectionsand said upper bottom portion having a plurality of spaced upperrecesses extending longitudinally straight along a central axis foraccepting said projections.
 2. An assembly as set forth in claim 1including a plurality of dimples for abutting said upper top portion atthe interior of said upper manifold to form a snap fit through saidopening.
 3. An assembly as set forth in claim 2 wherein said partitionhas a plurality of spaced and alternating locking tabs for abutting saidupper top portion at the exterior of said upper manifold.
 4. Theassembly as set forth in claim 3 wherein said dimple has a ramp-likeshape when looking at a plane normal to said partition.
 5. The assemblyas set forth in claim 1 wherein said upper bottom portion of said uppermanifold define a plurality of spaced upper tube slots.
 6. The assemblyas set forth in claim 5 including a plurality of tubes extending betweenupper and lower tube ends and parallel and spaced from one another fordefining a plurality of air passages there between and said upper tubeend of each of said tubes is disposed in one of said upper tube slots ofsaid upper manifold.
 7. The assembly as set forth in claim 6 including alower manifold extending in spaced and parallel relationship with saidupper manifold and defining a plurality of lower tube slots being spacedand aligned with said upper tube slots and said lower tube ends of eachof said tubes extending into corresponding said lower tube slots of saidlower manifold to establish fluid communication between said passages ofsaid tubes and said lower manifold.
 8. The assembly as set forth inclaim 7 wherein said tube slots include a plurality of rows of tubeslots one on each side of said central axis.
 9. The assembly as setforth in claim 8 wherein said tubes include a plurality of tube rows oneon each side of said central axis and are disposed in said tube slots.10. The assembly as set forth in claim 9 wherein said lower manifolddefines an interior and has a lower top portion and a lower bottomportion and wherein said top portions of said manifolds have at leastone slot.
 11. The assembly as set forth in claim 10 including at leastone separator for insertion into said slots in said top portions of saidmanifolds to divide the interior of said manifolds into more than twochambers.
 12. The assembly as set forth in claim 11 wherein said topportions have a curved shape.
 13. The assembly as set forth in claim 12wherein said tubes have a cross-section defining flat sides and roundends.
 14. The assembly as set forth in claim 13 including an air findisposed between and brazed to of said tubes and extending between saidupper and lower manifolds for dissipating heat from said tubes.
 15. Theassembly as set forth in claim 7 including an end cap disposed on eachend of said manifolds.
 16. The assembly as set forth in claim 1 whereinsaid partition defines a plurality of holes for conveying refrigerantthrough said manifold.
 17. A method of forming a manifold assembly for aheat exchanger including the steps of: forming an upper manifolddefining an interior and having an upper top potion defining an upperopening in the center of the upper top portion and an upper bottomportion defining a plurality of spaced upper tube slots; dividing theupper manifold to define a plurality of chambers in the interior of theupper manifold; and joining the partition and the upper manifold. 18.The method as set forth in claim 17 further including the step of:wherein said joining step includes projecting a dimple from thepartition and providing an opening in the upper top portion andelastically forming the opening by sliding the dimple through theopening.
 19. The method as set forth in claim 18 further including thestep of: permanently fixing at least one locking tab disposed on thepartition to the exterior of the upper top portion of the upper manifoldwherein the permanent fixing is further defined as brazing.
 20. Themethod as set forth in claim 19 further including the step of: forming aplurality of tubes extending between upper and lower tube ends anddefining a plurality of air passages there between.
 21. The method asset forth in claim 20 further including the step of: inserting the uppertube end of each tube into one of the upper tube slots of the uppermanifold and to establish fluid communication between the passages ofthe tubes and the chambers of the upper manifold.
 22. The method as setforth in claim 21 further including the step of: forming a lowermanifold defining an interior and having an upper top potion definingand an upper bottom portion defining a plurality of spaced upper tubeslots aligning with the upper tube slots;
 23. The method as set forth inclaim 22 further including the step of: inserting the lower tube end ofeach of the tubes into the corresponding lower tube slot of the lowermanifold to establish fluid communication between the passages of eachtube and the lower manifold.
 24. The method as set forth in claim 23further including the step of: forming an air fin between adjacent tubesto dissipate heat from the tube.
 25. The method as set forth in claim 24further including the step of: inserting a separator into the topportions for dividing the interior of the manifolds into more than twochambers.
 26. A heat exchanger assembly comprising: an upper manifolddefining an interior and having an upper top portion and an upper bottomportion; said top portion having a curved shape and an upper opening inthe center of said upper top portion; a lower manifold being spaced andparallel from said upper manifold; said upper bottom portion of saidupper manifold defining a plurality of spaced upper tube slots; saidlower manifold defining a plurality of spaced lower tube slots; aplurality of tubes having flat sides and extending between upper andlower tube ends in said upper and lower tube slots and parallel andspaced from one another for defining a plurality of air passages therebetween; said tube slots including a plurality of rows of tube slots oneon each side of said central axis; said tubes include a plurality oftube rows disposed in said tube slots to define a plurality of passages;an air fin disposed between and brazed to said flat sides of said tubesand extending between said upper and lower manifolds for dissipatingheat from said tubes; said lower manifold defining an interior andhaving a lower top portion and a lower bottom portion and said topportions of said manifolds having at least one slot; at least oneseparator for insertion into said slots in said top portions to dividethe interior of said manifolds into more than two chambers; an end capdisposed on each end of said manifolds; a partition disposed in saidupper manifold to define a plurality of chambers in the interior of saidupper manifold; said partition having a plurality of spaced andalternating locking tabs for abutting the top portion at the exterior ofsaid upper manifold and a plurality of spaced dimples for abutting thetop portion at the interior of said upper manifold to form a snap fitthrough said opening; said dimples having a ramp-like shape when lookingat a plane normal to said partition; and said partition having aplurality of spaced projections and said upper bottom portion having aplurality of spaced upper recesses extending longitudinally straight foraccepting said projections; and said partition defines a plurality ofholes for conveying refrigerant through said manifold.
 27. The assemblyas set forth in claim 26 wherein said tubes including a plurality oftube rows one on each side of said central axis.